Fine finishing entails increased percentage contact area, less friction, and less wear. The magnetorheological finishing is a precision process to obtain the fine finishing on the workpiece surface for improved functional applications. So, the rotary rectangular core-based magnetorheological finishing process is utilized for the precise finishing of the cylindrical external surfaces. The rotary-rectangular shaped tool core tip surface provides the uniformly magnetic flux concentration that further benefit to offer the uniform fine finishing on the cylindrical work-part's external surface. In this work, a theoretical model is developed to predict the reduction in the surface asperities during the magnetorheological finishing of the external cylindrical surfaces. The rotational speed of the rectangular tool core on the rotating cylindrical work-part enhances the relative speed of active abrasives, which decreases the pitch, helix angle, and increases the helical path length. These results enhance the uniform precise finishing on the cylindrical work-parts and also enhances the process performance. For validation of the theoretical roughness model, the experiments have been performed on the cylindrical external surface of the H13 die steel workpiece. The percentage error between the experimentally obtained Ra value and theoretical Ra value is found to be −4.76% to 3.06%, which shows the good agreement between the theoretical model and experimental results. It also shows the practicality and accuracy of the present process while finishing the H13 die steel and it is useful for many industrial applications.

中文翻译：

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外圆柱表面磁流变精加工的理论研究以提高性能

精加工需要增加接触面积百分比、减少摩擦和减少磨损。磁流变精加工是在工件表面获得精细精加工以改善功能应用的精密工艺。因此，基于旋转矩形磁芯的磁流变精加工工艺用于圆柱外表面的精密精加工。旋转矩形刀芯尖端表面提供了均匀的磁通量集中，进一步有利于在圆柱形工件的外表面上提供均匀的精加工。在这项工作中，开发了一个理论模型来预测在外圆柱表面的磁流变精加工过程中表面粗糙度的减少。旋转圆柱形工件上矩形刀芯的旋转速度提高了活性磨料的相对速度，从而减小了螺距、螺旋角并增加了螺旋路径长度。这些结果提高了对圆柱形工件的均匀精确精加工，也提高了加工性能。为了验证理论粗糙度模型，在 H13 模具钢工件的圆柱外表面上进行了实验。发现实验获得的Ra值与理论Ra值之间的百分比误差为-4.76%至3.06%，这表明理论模型与实验结果之间具有良好的一致性。它还在精加工 H13 模具钢时显示了当前工艺的实用性和准确性，并且它可用于许多工业应用。